Fabrics made with warp component formed of spun yarn that is made with polyester fibers or acrylic fibers

ABSTRACT

A fabric comprising a warp component and a weft component. The warp component is made of a spun yarn that is 100% polyester fiber. The 100% polyester fiber spun yarn may be combined with one or more other yarns to form the warp component, such as a texturized polyester yarn but not limited thereto. Alternatively, the warp component is made of a spun yarn that is 100% acrylic fiber. The 100% acrylic fiber spun yarn may be combined with one or more other yarns to form the warp component, such as a texturized polyester yarn but not limited thereto. The weft component of the fabric may be formed of using one or more of manmade fibers and/or natural fibers. The fabric may be used to make bedding products.

1. FIELD OF THE INVENTION

The present invention relates to fabrics and fabric products. More specifically, the present invention relates to fabrics, including bedding fabrics, comprising a warp component and a weft component. More particularly, the present invention also relates to fabrics comprising the warp component formed of a spun yarn that is made of or that includes polyester fibers or acrylic fibers.

2. DESCRIPTION OF THE PRIOR ART

There is a wide array of fabric products for a wide array of uses. Examples of fabric products that a person may come in contact with include bedding, clothing, and towels. Of course, other fabric products exist. Fabric products comprising such consumer products must comply with a range of characteristics of interest to people. These characteristics include, but are not limited to, the feel or “hand” of the fabric, the strength of the fabric, the appearance of the fabric, the durability of the fabric, the ease of cleaning the fabric, minimum wrinkling, if any, production convenience, and pricing. These are not the only characteristics of interest, but they represent primary ones of interest.

These desired fabric characteristics tend to compete with one another, with some characteristics more desirable than others dependent on the particular products made with the fabrics. That is, for example, it may be more important to have good durability and less feel concern for a towel, but better feel and less durability concern for a shirt. These competing characteristics have led fabric manufacturers to combine different fabric components together to take advantage of the beneficial features of those components in a single fabric product. However, there continue to exist limitations on the combination of characteristics that can reside in a single fabric product.

Commercial woven and nonwoven fabrics are typically comprised of yarns made of a plurality of fibers that are twisted together. The yarns may be made of natural fibers, such as cotton, and manmade fibers, such as synthetic polymers formed into fibers. These fabrics are typically produced with one or more yarns that are joined together by weaving, stitching or other forms of joining. The yarns selected to make fabrics are chosen based on the desired characteristics of the fabric. Synthetic yarns are generally made of any of a variety of polymers and are made with fibers of different thicknesses and shapes. The yarns are formed of a plurality of fibers twisted together into a bundle.

Woven fabrics are formed by weaving together two or more yarns and/or threads in which there is a warp component and a weft component of the weave. The warp component is considered to be the lengthwise component and the weft component is considered to be the transverse component relative to the warp component. The warp component establishes the basis of the fabric and is held in tension on a frame or loom. The number and characteristics of the threads or yarns used to form the warp component are selectable. The weft component, which is sometimes referred to as the fill, is woven through the warp component generally at a substantially right angle to what constitutes the length of the warp component. The number and characteristics of the threads or yarns used to form the weft component are also selectable.

Given that the origin of the fabric starts with the warp component, it is not surprising that the warp component predominantly defines the characteristics of the fabric, although the weft component is certainly influential. It is widely understood in the fabric manufacturing industry and in the bedding manufacturing industry in particular, that the warp component must be quite strong and fairly resistant to extensive stretching since it establishes the backbone or the primary structure of the fabric. For that reason and others, the warp component has primarily been made entirely or substantially of natural fibers, such as wool, flax and cotton. Cotton is the natural fiber of choice for the warp component of bedding products given its desirable feel and strength characteristics. Manmade or synthetic yarns are generally used as a secondary component of a fabric product, particularly bedding, to enhance or at least maintain the characteristics of natural fibers while reducing the cost of making the fabric.

Synthetic yarns are identified by the polymer used, weight per unit length, referred to as its Denier, and the number of fiber filaments used to make it. For example, a 75×72 polyester yarn has a Denier of 75 made with 72 filaments twisted together. A “fiber” is a unit of matter, either natural or manmade that forms the basic element of fabrics and other textile structures. A “filament” on the other hand, is a fiber of indefinite length. It can be found in natural materials, such as silk, for example, but is more commonly available in manufactured materials. Manufactured fibers are extruded into filaments that are converted into filament yarn, staple, or tow. A “filament yarn” is composed of continuous filaments that may or may not be twisted together. A “spun yarn” is a yarn of staple fibers usually held together by twist or a melt-spun fiber before it is drawn. A “textured yarn” is a yarn that develops stretch and bulk on subsequent processing.

As noted, fabrics are made with combinations of materials because it is difficult to provide all desired fabric characteristics with a single yarn formed with a single natural or synthetic material. For example, a fabric made of a polyester yarn tends to be wrinkle-free while a fabric made of a cotton yarn has a desirable feel for most users. Polyester yarns tend to be easier to manufacture and, so, tend to be less expensive than cotton yarns to make into fabric products. Additional features and limitations of note regarding materials used to make fabrics such as bedding fabrics in particular include, but are not limited to:

-   -   Polyester is cheaper than cotton;     -   Filament (manmade) yarn is easier to make than natural (cotton)         yarn, so that manufacturers tend to prefer using filament yarns,         which can reduce the price of fabrics that contain primarily         natural yarns;     -   Existing Chief Value Cotton (CVC), which comprises a majority of         cotton and a minority of polyester filaments, while desirable to         a certain extent, can still wrinkle;     -   The tensile strength and durability of fabrics made primarily         with manmade fibers is less than those made of manmade         filaments;     -   CVC fabrics tend to be less shiny than fabrics made completely         of manmade materials, and cotton fabrics have essentially no         shine;     -   Cotton yarns are not as “silky” as polyester yarns and so         polyester yarns may be softer to the touch;     -   Cotton is difficult to wash and to dry, and harder to maintain         wrinkle-free without ironing;     -   Cotton tends to pill;     -   Cotton is generally perceived to feel better to the touch than         does a manmade yarn;     -   The price of cotton is more variable than is desired by         manufacturers, that is, cotton prices vary substantially         depending on the crop and other seasonal factors, which are hard         to predict, while manmade fibers tend to be more price stable;     -   It is more difficult to integrate anti-microbial and/or         anti-bacterial features into a fabric made of cotton as it         requires treatment with a chemical additive that can wash away         after relatively few washings; and     -   Cotton is not as durable as manmade fiber, and so its existence         as the majority component in a fabric product is not suitable         for all applications, including in the hospitality industry, for         example.

What is needed is a fabric product that combines the best features of manmade fibers and natural fibers. In particular, what is needed is a fabric product that is affordable to make and sell, that has good feel with limited pilling and is durable for the anticipated usage. What is further needed is such a fabric and related method of making such a fabric that can be used to produce affordable, high quality, bedding as well as other fabric products.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a fabric product that combines the best features of manmade fibers and natural fibers. It is also an object of the invention to provide a fabric product that is affordable to make and sell, that has good feel with limited pilling and is durable for the anticipated usage. A further object of the invention is to provide such a fabric and related method of making such a fabric that can be used to produce affordable, high quality, bedding, and other fabric products. In particular, the bedding includes flat sheets, fitted sheets, duvets, pillow covers, or any other similar article, all sold individually or in any combination thereof.

These and other objects are achieved with the present invention, which is a fabric product having a warp component that is formed solely or primarily of one or more spun yarns made of manmade fibers. The manmade fibers are polymeric fibers including polyester, nylon and acrylic. The manmade fibers are formed into spun yarns and used as the warp component of a fabric. A manmade continuous filament yarn may also be used in combination with a manmade fiber-based spun yarn to form the warp component of the fabric. Natural fibers that may be used to form a portion or all of the weft component include but are not limited to cotton, wool, silk, and alpaca.

The fabric of the present invention is formed by weaving or knitting together warp and weft components in the form of yarns, wherein the yarns are made of fibers comprising at least the one or more manmade fibers and the one or more natural fibers with the one or more yarns made with manmade fibers being the warp component of the fabric. The warp yarn includes at least one spun yarn. In one instance, the one or more manmade yarns is a polyester yarn, and the one or more natural yarns is a cotton yarn. The one or more manmade yarns may also be acrylic yarn. When the weft component includes a cotton yarn, the cotton yarn may be chosen from the group consisting of 100% cotton, Indian cotton, Egyptian cotton, Pima cotton, Supima cotton, and cotton mixed with a manmade or a cellulosic fiber. The cotton can have a weight in the range of NE 20 to NE 120.

The polyester spun yarn is 100% polyester that may be used alone or in combination with one or more other yarns, such as a texturized or multi-texturized polyester yarn, and a yarn of polyester mixed with cotton or cellulosic fiber. The polyester yarn may be formed of filaments in the range of 8 Denier to 250 denier and the filament count is in the range of 14 to 324. The acrylic spun yarn is 100% acrylic that may be used alone or in combination with one or more other yarns, such as a texturized or multi-texturized polyester yarn, and a yarn of acrylic mixed with cotton or cellulosic fiber. The fabric can be formed into bedding with a thread count in the range of 120 to 2500 in a manner known to those of skill in the art of making bedding.

The invention is a fabric having a warp component and a weft component, wherein the warp component is a spun yarn made of 100% polyester fibers. The warp component may include one or more other yarns combined with the spun yarn made of 100% polyester fibers. For example, a second yarn may be combined substantially in parallel with the spun yarn made of 100% polyester fibers, wherein the second yarn is 100% polyester texturized yarn, and wherein a blend ratio of the 100% polyester spun yarn and the 100% polyester texturized yarn is in a range of 99 to 1 to 1 to 99 by weight. Further, wherein the warp component may also include a third yarn substantially in parallel with the second yarn and the spun yarn made of 100% polyester fibers, wherein the third yarn is a spun yarn that is 100% acrylic yarn, wherein a blend ratio of the 100% polyester spun yarn, the 100% polyester texturized yarn, and the 100% acrylic spun yarn is in any of the ranges of 98 to 1 to 1, 1 to 98 to 1, and 1 to 1 to 98, by weight. The weft component joined together with the warp component made of a spun yarn of 100% polyester fibers may be any of:

-   -   one or more of: a 100% polyester spun yarn, a 100% polyester         filament yarn, a cotton yarn, a Modal yarn, an Excel yarn, and a         Rayon yarn;     -   a yarn made of a blend of two or more of: cotton fibers,         polyester fibers, viscose fibers, Modal fibers, Excel fibers,         linen fibers, hemp fibers, wool fibers, and acrylic fibers; and     -   100% cotton, wherein the 100% cotton is selected from Indian         cotton, Egyptian cotton, Pima cotton, Supima cotton, cotton         mixed with a polyester fiber, and cotton mixed with cellulosic         fiber.

The invention is alternatively a fabric having a warp component and a weft component, wherein the warp component is spun yarn made of 100% acrylic fibers. The warp component may include one or more other yarns combined with the spun yarn made of 100% acrylic fibers. For example, a second yarn may be combined substantially in parallel with the spun yarn made of 100% acrylic fibers, wherein the second yarn is 100% polyester texturized yarn, and wherein a blend ratio of the 100% acrylic spun yarn and the 100% polyester texturized yarn is in a range of 99 to 1 to 1 to 99 by weight. Alternatively, the second yarn of the warp component may be a spun yarn made of 100% polyester fibers, and wherein a blend ratio of the 100% acrylic fibers spun yarn and the 100% polyester fibers spun yarn is in a range of 99 to 1 to 1 to 99 by weight. The weft component joined together with the warp component made of a spun yarn of 100% acrylic fibers may be any of:

-   -   one or more of: a 100% polyester spun yarn, a 100% polyester         filament yarn, a cotton yarn, a Modal yarn, an Excel yarn, and a         Rayon yarn;     -   a yarn made of a blend of two or more of: cotton fibers,         polyester fibers, viscose fibers, Modal fibers, Excel fibers,         linen fibers, hemp fibers, wool fibers, and acrylic fibers; and     -   100% cotton, wherein the 100% cotton is selected from Indian         cotton, Egyptian cotton, Pima cotton, Supima cotton, cotton         mixed with a polyester fiber, and cotton mixed with cellulosic         fiber.

The fabrics configured as described herein have characteristics of maximum softness, performance attributes, durability, sheen, hand, feel, and other attributes of interest to a range of consumers while remaining cost effective to produce.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a close-up view of a fabric of the present invention showing a general form of the fabric as including a warp component and a weft component in a plain weave configuration.

FIG. 2 is a flow diagram showing the general steps, some of which are optional, that may be taken to carry out a method of making the fabric of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

As shown in FIG. 1, the present invention is a fabric 10 that may be single-ply or multi-ply. The fabric 10 is formed of a combination of yarns with the yarns being made of fibers. The fabric is made of a warp component 12 and a weft component 14. The warp component 12 is made of one or more yarns, and the weft component 14 is made of one or more yarns. The warp component 12 are either formed of 100% polyester fiber spun yarn alone or in combination with one or more other yarns, or 100% acrylic fiber spun yarn alone or in combination with one or more other yarns. For example, a continuous polyester filament yarn may be combined with the polyester fiber spun yarn, the acrylic fiber spun yarn or both. The continuous polyester filament yarn may be texturized, multi-texturized or untexturized. The weft component 14 may be any one or more of yarns made with manmade fibers, natural fibers, or combinations thereof. For example, the weft yarns may be cotton yarn, Modal yarn, Excel yarn, Rayon yarn, silk yarn, and cellulosic yarn, and combinations thereof, but not so limited.

The warp and weft yarns may be woven together in any of the following weaves: a) plain; 2) bucket; c) satin; d) satin stripe 5/1; e) satin 4/1; f) 4/1 satin stripe; g) 4/1 satin swiss dot; h) 4/1 Jacquard; i) 5/1 Jacquard; j) 5/1 Jacquard satin; k) 2/1 rib; l) 2/2 rib; m) 2/3 rib; n) twill; o) percale; and p) oxford.

The 100% polyester fibers of the spun yarn used to form the warp component 12 of the fabric 10 has characteristics of: a) Denier in the range of about 0.5 to about 10; and b) cut fiber length in the range of about 15 millimeters to about 61 millimeters. The fiber count of then spun polyester (Number English or “NE”) is preferably in the range of about NE 2 to about NE 120. The 100% polyester fibers may be in the form of circular, trilobal; and/or at least partially voided. An advantage of using the polyester spun fiber yarn as the warp component is that the fabric ends up with improved temperature control capability; anti-bacterial, antiviral; and moisture management, with those fibers located at the warp location rather than solely at the weft location.

The 100% polyester fibers of the spun yarn used to form the warp component 12 of the fabric 10 may be produced in any of a number of ways known to those skilled in the art of polyester spun fiber manufacture including: a) open end spinning; b) ring frame spinning; c) rotor spun spinning; d) core spinning; e) compact spinning; f) vortex spinning; and g) jet spinning. Additionally or alternatively, the 100% polyester fiber spun yarn of the warp component 12 may be combined with one or more other yarns, such as yarns made of: a) acrylic fibers; b) nylon fibers; c) rayon; d) viscose fibers; and d) Modal fibers. The spun yarn of the warp component 12 may alternatively be made of 100% acrylic fibers. The 100% acrylic fiber spun yarn of the warp component 12 may be combined with one or more other yarns, such as yarns made of: a) polyester fibers; b) nylon fibers; c) rayon; d) viscose fibers; and d) Modal fibers. In the configuration of the invention wherein the fabric 10 includes a filament yarn, the filament yarn may be a polyester yarn, a rayon yarn, an acrylic yarn, and/or a yarn coated with a desirable component. Other additives may be included with the warp component 10 and/or the weft component 14 including, for example, anti-microbial, anti-bacterial, and moisture moving component, such as silver fibers, for example.

The fabric 10 of the present invention that combines the warp component 12 formed with a spun yarn that is made of 100% polyester fiber, 100% acrylic fiber, or a combination of those two and/or other yarns, along with the weft component 14 eliminates some undesirable characteristics of natural fibers including, but not limited to, a reduction in pilling and an increase in durability.

When the weft component 14 of the fabric includes a yarn made partially or completely of cotton, the cotton may be selected from the group including 100% cotton, Indian cotton, Egyptian cotton, Pima cotton, Supima cotton, and CVC. The cotton count is preferably in the range of about NE 20 to about NE 120. The natural fiber of the weft component 14 may additionally or alternatively include silk, wool linen, and flax.

A fabrication method 100 of the present invention suitable for forming the fabric 10 of the first embodiment of the invention includes a plurality of steps, several of which are optional, in the fabrication of the first embodiment of the fabric. Generally, the steps of the method 100 may be carried out as shown in FIG. 2. In step 110, one or more warp yarns are selected wherein the warp yarns are made of either or both of 100% polyester fibers and 100% acrylic fibers, and optionally other yarns, and in step 112, one or more weft yarns are selected, wherein the weft yarns may be formed of or include one or more natural fibers. In step 114, a weave or knit is chosen. In step 116, the fabric 10 is formed by weaving or knitting the selected warp yarn/yarns and selected weft yarn/yarns together. For purposes of the description of the present invention, the two terms may be used interchangeably, such that when it is stated that the method 100 includes a weaving step, that means weaving or knitting the yarns together. In optional step 118, the fabric 10 may be sized simultaneously with the step 116 of weaving. In optional step 120, the fabric 10 may be pre-treated to prepare it for subsequent dyeing and/or printing, for example, or for any other purpose. In optional step 120, the woven fabric 10 may be further processed as desired to produce a finished product, such as bedding, for example.

The skilled artisan will recognize that the warp component 12 and weft component 14 may be woven or knitted to form the fabric 10 by using any one or more of a variety of techniques that are well known in the art. For example, the skilled artisan will recognize that such weaving may be carried by using an air jet frame, and that such knitting may be carried out by using a loop circular frame, but the method 100 is not restricted or limited to using these exact type of machines.

The skilled artisan will recognize that the fabric 10 of the present invention may be used for any one or more of a large variety of purposes and to form partially or wholly any one or more of a large variety of products. For example, the fabric 10 may be used to form apparel or non-apparel products partially or wholly such as bedding, towels, and clothing, but not limited thereto.

The present invention has been described with respect to various examples. Nevertheless, it is to be understood that various modifications may be made without departing from the spirit and scope of the invention as described by the following claims. 

What is claimed is:
 1. A fabric comprising: a warp component; and a weft component, wherein the warp component is a spun yarn made of 100% polyester fibers.
 2. The fabric of claim 1, wherein the warp component may include one or more other yarns combined with the spun yarn made of 100% polyester fibers.
 3. The fabric of claim 2, wherein the warp component further includes a second yarn substantially in parallel with the spun yarn made of 100% polyester fibers, wherein the second yarn is 100% polyester texturized yarn, and wherein a blend ratio of the 100% polyester spun yarn and the 100% polyester texturized yarn is in a range of 99 to 1 to 1 to 99 by weight.
 4. The fabric of claim 3, wherein the warp component further includes a third yarn substantially in parallel with the second yarn and the spun yarn made of 100% polyester fibers, wherein the third yarn is a spun yarn that is 100% acrylic yarn, wherein a blend ratio of the 100% polyester spun yarn, the 100% polyester texturized yarn, and the 100% acrylic spun yarn is in any of the ranges of 98 to 1 to 1, 1 to 98 to 1, and 1 to 1 to 98, by weight.
 5. The fabric of claim 1, wherein the weft component is made of any of: one or more of: a 100% polyester spun yarn, a 100% polyester filament yarn, a cotton yarn, a Modal yarn, an Excel yarn, and a Rayon yarn; a yarn made of a blend of two or more of: cotton fibers, polyester fibers, viscose fibers, Modal fibers, Excel fibers, linen fibers, hemp fibers, wool fibers, and acrylic fibers; and 100% cotton, wherein the 100% cotton is selected from Indian cotton, Egyptian cotton, Pima cotton, Supima cotton, cotton mixed with a polyester fiber, and cotton mixed with cellulosic fiber.
 6. A fabric comprising: a warp component; and a weft component, wherein the warp component is spun yarn made of 100% acrylic fibers.
 7. The fabric of claim 6, wherein the warp component may include one or more other yarns combined with the spun yarn made of 100% acrylic fibers.
 8. The fabric of claim 7, wherein the warp component further includes a second yarn substantially in parallel with the spun yarn made of 100% acrylic fibers, wherein the second yarn is 100% polyester texturized yarn, and wherein a blend ratio of the 100% acrylic spun yarn and the 100% polyester texturized yarn is in a range of 99 to 1 to 1 to 99 by weight.
 9. The fabric of claim 7, wherein the warp component further includes a second yarn substantially in parallel with the spun yarn made of 100% acrylic fibers, wherein the second yarn is a spun yarn made of 100% polyester fibers, and wherein a blend ratio of the 100% acrylic spun yarn and the spun yarn made of 100% polyester fibers is in a range of 99 to 1 to 1 to 99 by weight.
 10. The fabric of claim 6, wherein the weft component is made of any of: one or more of: a 100% polyester spun yarn, a 100% polyester filament yarn, a cotton yarn, a Modal yarn, an Excel yarn, and a Rayon yarn; a yarn made of a blend of two or more of: cotton fibers, polyester fibers, viscose fibers, Modal fibers, Excel fibers, linen fibers, hemp fibers, wool fibers, and acrylic fibers; and 100% cotton, wherein the 100% cotton is selected from Indian cotton, Egyptian cotton, Pima cotton, Supima cotton, cotton mixed with a polyester fiber, and cotton mixed with cellulosic fiber. 